Apparatus and method for control of print gap

ABSTRACT

Gas bearing systems, print gap control systems, and methods of print gap control are provided. The gas bearing systems can accommodate one or more print module packages. The systems and methods can be used for inkjet and/or thermal printing applications such as manufacturing organic light emitting devices (OLEDs). Gas bearing systems can employ one or more of pressurized gas and vacuum. For oxygen-sensitive applications, an inert gas, such as nitrogen gas, can be employed as the pressurized gas. Fluid channels and apertures of the gas bearing systems can be varied in terms of size and relative position to one another. Fluid channels and apertures can be grouped and paired with one or more manifolds and ultimately a pressurized gas and/or vacuum source.

RELATED APPLICATIONS

The present application is a continuation case of U.S. Ser. No.15/080,407, filed Mar. 24, 2016. U.S. Ser. No. 15/080,407, is acontinuation case of U.S. Ser. No. 14/807,628 filed Jul. 23, 2015, whichissued as U.S. Pat. No. 9,302,513 on Apr. 5, 2016. U.S. Pat. No.9,302,513 is a divisional application of U.S. Ser. No. 13/570,154, filedAug. 8, 2012, which issued as U.S. Pat. No. 9,120,344 on Sep. 1, 2015.U.S. Pat. No. 9,120,344 claims the benefit of U.S. Provisional PatentApplication No. 61/521,604, filed Aug. 9, 2011. All related applicationscited in this section are incorporated herein by reference in theirentirety.

FIELD

The present teachings relate to thin-film printing apparatuses andmethods.

BACKGROUND

In a variety of circumstances, it can be beneficial for a printhead tomaintain a tightly controlled gap between its transfer surface, ordischarge nozzle, and a substrate surface on which the printhead is toprint a material. Such control is especially important in printing witha thermal printing printhead devised for deposition of a dry ink withoutcontacting the surface on which the dry ink is to be deposited. If theprinthead is too far away from the substrate surface, the printing canbe too diffuse. If the printhead is too close to the substrate surface,printing can be too granular. When too close, the printhead may evencontact the substrate, resulting in damage to both the substrate and theprinthead. Gap control is also important in inkjet printing between theinkjet printhead and a substrate. Therefore, it is desirable to controlthe print gap between the substrate and the printhead in both thermaland inkjet printing systems, to optimize printing results and theprinting process.

SUMMARY

According to various embodiments, the present teachings relate to a gasbearing system that can be used for holding a printhead and print modulepackage and for maintaining a tightly controlled gap between thetransfer surface of the printhead and a substrate onto which a materialis to be printed. The system comprises a housing having a sidewall thathas an exterior surface and an interior surface. The sidewall defines aninterior cavity configured to receive a print module package. Theinterior surface can terminate at an opening to the interior cavity. Thesidewall can also have an end surface between its exterior surface andits interior surface, and the end surface can comprise a first pluralityof apertures and a second plurality of apertures. A first plurality offluid channels can be included in the sidewall and can extend from thefirst plurality of apertures, into the sidewall and into fluidcommunication with a first manifold. The first manifold can be internalto the sidewall, external, or both. A second plurality of fluid channelscan be included in the sidewall and can extend from the second pluralityof apertures, into the sidewall, and into fluid communication with asecond manifold. The second manifold can be internal to the sidewall,external, or both. The first manifold can be in fluid communication withan environment outside of the housing, for example, via a first port.The second manifold can be in fluid communication with an environmentoutside of the housing, for example, via a second port.

According to various embodiments, a print gap control system is providedthat comprises a gas bearing system as described herein, and a substratecomprising a first planar surface. The system can be configured suchthat an end surface of the gas bearing lies in a first plane, at leastone inkjet printhead or at least one transfer surface of a thermalprinting printhead lies in a second plane, and the first planar surfaceof the substrate lies in a third plane. The first, second, and thirdplanes can be substantially parallel to one another. A gas bearing gapcan be defined by a distance between the first plane and the thirdplane. A print gap can be defined by a distance between the second planeand the third plane. At least one of the end surface, the transfersurface, and the first planar substrate surface of the substrate can beadjustable to control a size of the print gap, a size of the gas bearinggap, or both. It is to be understood that in some embodiments the printgap can be controlled by controlling the gas bearing gap.

According to various embodiments of the present teachings, a method isprovided that comprises positioning a print module package with respectto a substrate and printing a material onto the substrate by using theprint module package. The positioning can be accomplished with a gasbearing system as described herein, for example, a system comprising ahousing wherein the housing comprises a sidewall that defines aninterior cavity. The sidewall can have an exterior surface and aninterior surface and the print module package can be received within theinterior cavity. The interior surface can terminate at an opening to theinterior cavity. The method can comprise mounting a print module packagein the interior cavity. The sidewall can further have an end surfacebetween the exterior surface and the interior surface, and the endsurface can comprise a first plurality of apertures and a secondplurality of apertures. The sidewall can further comprise a firstplurality of fluid channels extending from the first plurality ofapertures into the sidewall and communicating with a first manifold andthe method can comprise supplying a pressurized gas source to the firstmanifold and from the first manifold to the first plurality of fluidchannels. In addition, the sidewall can comprise a second plurality offluid channels extending from the second plurality of apertures into thesidewall and communicating with a second manifold and the method cancomprise causing a vacuum from the second manifold to a source of vacuumand from the second plurality of fluid channels to the second manifold.The first manifold can be in fluid communication with an environmentoutside of the housing, for example, via a first port, and the secondmanifold can be in fluid communication with an environment outside ofthe housing, for example, via a second port. The method can compriseusing a combination of pressurized gas and vacuum, to and from the firstand second pluralities of apertures, to control a print gap.

BRIEF DESCRIPTION OF THE DRAWINGS

A better understanding of the features and advantages of the presentdisclosure will be obtained by reference to the accompanying drawings,which are intended to illustrate, not limit, the present teachings.

FIG. 1 is a cross-sectional side view of a gas bearing system, a printmodule package positioned therein, a substrate to be printed on, and asubstrate support, in accordance with various embodiments of the presentteachings.

FIG. 2 is a cross-sectional side view of a gas bearing system, printmodule package positioned therein, substrate, and substrate positioningsystem, in accordance with various embodiments of the present teachings.

FIG. 3 is a bottom, perspective, exploded view of a gas bearing systemin accordance with various embodiments of the present teachings.

FIG. 4 is a left, bottom, perspective view of the gas bearing systemshown in FIG. 3, in an assembled state, and a print module package to beadjustably mounted therein.

FIG. 5 is a perspective view of the gas bearing system shown in FIG. 3,upside down and in an assembled state, and a print module packageadjustably mounted or secured therein.

FIG. 6 is a right, bottom perspective view of the gas bearing system andprint module package shown in FIG. 5,

FIG. 7 is a perspective view of the gas bearing system and print modulepackage shown in FIGS. 5 and 6, secured to a rotating actuator andpositioned for carrying out a thermal printing operation.

DETAILED DESCRIPTION OF THE DISCLOSURE

According to various embodiments of the present teachings, the gasbearing system comprises a housing having a sidewall and the sidewallcomprises an exterior surface and an interior surface. The sidewalldefines an interior cavity configured to receive a print module package.The interior surface can terminate at a top, a bottom, or both, anddefine an opening to the interior cavity. The interior cavity can form athrough-hole through the housing or can have only a single opening atone end. The sidewall can also have an end surface between its exteriorsurface and its interior surface, and the end surface can comprise afirst plurality of apertures and a second plurality of apertures. Afirst plurality of fluid channels can be included in the sidewall andcan extend from the first plurality of apertures, into the sidewall, andinto fluid communication with a first manifold. A second plurality offluid channels can be included in the sidewall and can extend from thesecond plurality of apertures, into the sidewall, and into fluidcommunication with a second manifold. Each of the first manifold and thesecond manifold can independently be internal to the sidewall, externalto the sidewall, or both. The first manifold can be in fluidcommunication with an environment outside of the housing, for example,via a first port. The second manifold can be in fluid communication withan environment outside of the housing, for example, via a second port.Conduits, such as tubing, can be in fluid communication with each of themanifolds and can be further connected to a supply of pressurized gas,to a vacuum source, or both. The first plurality of apertures and thesecond plurality of apertures can be arranged to surround the opening tothe interior cavity. The interior cavity can have a cross-sectionalshape that is square, rectangular, round, or of any other shape. Theapertures can surround the opening to the interior cavity on two sides,three sides, four sides, or at least five sides.

In some embodiments, the end surface of the sidewall can furthercomprise a third plurality of fluid channels extending into the sidewalland communicating with a third manifold that differs from the first andsecond manifolds. The third manifold can be in fluid communication withan environment outside of the housing, for example, via a third port.The third manifold can be in fluid communication with a source ofpressurized gas, a vacuum source, or both. The third manifold can be influid communication with the same source of pressurized gas that is influid communication with the first manifold, or in fluid communicationwith a different source of pressurized gas. The individual apertures ofthe first and second pluralities of apertures can be spaced apart fromadjacent apertures by a mean distance of from about 0.5 mm to about 20mm, for example, a mean distance of from about 1.0 mm to about 10 mm, offrom about 2.0 mm to about 8.0 mm, or of from about 3.0 mm to about 6.0mm. The apertures of the first and second pluralities of apertures canhave a mean diameter of from about 0.001 inch to about 0.1 inch, forexample, of from about 0.003 inch to about 0.075 inch, of from about0.005 inch to about 0.05 inch, or of from about 0.01 inch to about 0.04inch. In some embodiments, the first plurality of apertures can have amean diameter of from about 0.005 inch to about 0.025 inch and thesecond plurality of apertures can have a mean diameter of from about0.030 inch to about 0.090 inch.

According to various embodiments, the first plurality of fluid channelscan be in fluid communication with a pressurized gas source and thesecond plurality of fluid channels can be in fluid communication with avacuum source. The pressurized gas source can comprise a pressurizedinert gas source, for example, a source of nitrogen gas, a source of anoble gas, or a combination thereof.

In some embodiments, the housing can comprise a plurality of components,for example, a base plate, a manifold compartment mounted on the baseplate, and a face plate mounted on the manifold. In an exemplaryconfiguration, the face plate comprises the end surface. The base platecan comprise the first and second ports and the manifold compartment cancomprise the first and second manifolds. In some embodiments, the baseplate comprises a third port and the manifold compartment comprises athird manifold. In some embodiments, the base plate can comprise first,second, and third ports and the manifold compartment can comprise first,second, and third manifolds. In some embodiments, the manifoldcompartment or one or more of the manifolds can comprise one or more ofthe ports. A connector flange can be connected to the base plate andconfigured for connection to at least one of a support and an actuator.One or more of the components can define the sidewall or partiallydefine the sidewall, for example, a stack of components including a faceplate can together define the sidewall, the interior cavity, or both.

In some embodiments, the housing can provide a second opening to theinterior cavity. The second opening can be located opposite the firstopening such that the interior cavity can comprise a through hole thatextends through the entire housing. At least one print module packagecan be mounted in the interior cavity. In some cases, the at least oneprint module package can comprise at least one inkjet printhead or atleast one thermal printing printhead having at least one transfersurface, and at least one heater in thermal communication with the atleast one transfer surface. In some embodiments, the second openingallows exhaust to be vented from the interior cavity. The second openingcan enable print module package loading from a top of the system, from abottom of the system, or both. It is understood that the orientation ofthe gas bearing system can be varied and that designations such at topand bottom are intended to be relative and not absolute terms. In someembodiments, the features are reversed such that the second opening canenable the print module package to be loaded from a bottom of thesystem.

According to various embodiments, a print gap control system is providedthat comprises a gas bearing system as described herein, and a substratecomprising a first planar surface. The system can be configured suchthat the end surface lies in a first plane, the at least one transfersurface lies in a second plane, and the first planar substrate surfacelies in a third plane. The first, second, and third planes can besubstantially parallel to one another, that is, parallel to one anotheror skewed by less than 10° or less than 5° with respect to each other. Agas bearing gap can be defined by a distance between the first plane andthe third plane. A print gap can be defined by a distance between thesecond plane and the third plane. At least one of the end surface, theinkjet printhead or transfer surface, and the first planar substratesurface can be adjustable to control a size of the print gap, a size ofthe gas bearing gap, or both. The print gap can be controlledindependently and/or by controlling the size of the gas bearing gap. Agas bearing system can be positioned above, below, or above and belowthe substrate. The gas bearing system can comprise or be operablyassociated with one or more actuators to enable adjustment of theposition of the gas bearing system relative to the substrate and/orrelative to one or more inkjet printheads.

A second gas bearing system can be provided facing the first gas bearingsystem such that the substrate is positioned between the first gasbearing system and the second gas bearing system. The second gas bearingsystem can also comprise a plurality of pressurized gas channels andoptionally a plurality of vacuum channels. Pressurized gas channels andvacuum channels can be arranged in any desired configuration. In someembodiments, every other fluid channel or alternating fluid channelscomprise a pressurized channel and a vacuum channel. The second gasbearing, which can be mounted in a chuck, can provide temperaturecontrol for the substrate. That is, in addition to providing a force tothe substrate, the second gas bearing can transfer heat to and/or fromthe substrate to achieve heating and/or cooling of the substrate. Suchthermal control can be advantageous compared to direct contact with aheating element, for example, a heated chuck. Heating channels andcooling channels can be arranged in any desired configuration. In someembodiments, every other fluid channel can comprise a heating channel ora cooling channel. In some embodiments, alternating fluid channelscomprise a heating channel, a cooling channel, a heating channel, acooling channel, and so on. Thermal control can also be used to controlthe size of the substrate as heat can tend to expand the substrate andcooling can tend to contract the substrate. Maintenance of a constantsize is advantageous. Thermal size changes can be particularlysignificant for larger substrates, for example, thermal size changes aresignificant for Generation 8 size glass (2.2 m by 2.5 m). Uncontrolledthermal change of the substrate can deleteriously affect product qualityby shifting, horizontally and/or vertically, the deposition of ink onthe substrate. In some embodiments, the print gap can have a toleranceof about +/−10 μm, +/−7 μm, or +/−5 μm.

According to various embodiments of the present teachings, a method isprovided that comprises positioning a print module package with respectto a substrate and printing a material onto the substrate by using theprint module package. The positioning can be accomplished with a gasbearing system as described herein, for example, one comprising ahousing wherein the housing defines an interior cavity. The sidewall canhave an exterior surface and an interior surface and the print modulepackage can be received within the interior cavity. The interior surfacecan terminate at an opening to the interior cavity and the method cancomprise mounting the print module package in the interior cavity. Thesidewall can further have an end surface between the exterior surfaceand the interior surface, and the end surface can comprise a firstplurality of apertures and a second plurality of apertures. The methodcan comprise supplying pressurized gas to and through the firstplurality of apertures and drawing a vacuum through the second pluralityof apertures. The sidewall can further comprise a first plurality offluid channels extending from the first plurality of apertures into thesidewall and communicating with a first manifold. In addition, thesidewall can comprise a second plurality of fluid channels extendingfrom the second plurality of apertures into the sidewall andcommunicating with a second manifold. The method can comprise supplyinga pressurized gas to the first manifold and drawing a vacuum on thesecond manifold. The first manifold can be in fluid communication withan environment outside of the housing, for example, via a first port,and the second manifold can be in fluid communication with anenvironment outside of the housing, for example, via a second port.Tubing, piping, or other conduits can connect the first and secondmanifolds with sources of pressurized gas and vacuum, respectively. Insome embodiments, the first plurality of apertures and the secondplurality of apertures surround the opening to the interior cavity.

In some embodiments, the printing can comprise thermal printing, forexample, thermal printing that comprises inkjet printing followed bysolids transfer printing by sublimation or evaporation of solids usingthe print module package. Examples of thermal printing and print modulepackages that can be used in accordance with the present teachingsinclude those described, for example, in U.S. Patent ApplicationPublications Nos. US 2008/0308307 A1, US 2008/0311307 A1, US2008/0311289 A1, and US 2006/0115585 A1, which are incorporated hereinin their entireties by reference. The print module package can comprisea printhead transfer surface and/or inkjet nozzle orifice, the substratecan comprise a first surface, and the printhead transfer surface and/orthe inkjet nozzle orifice can face the substrate first surface and bespaced apart from one another by a print gap. The printhead transfersurface can receive ink deposited by inkjet printing, for example, froman inkjet printing subsystem. In some embodiments, one or more printheadtransfer surfaces are rotated to receive ink and/or rotated to face thesubstrate to be printed. In some embodiments, one or more inkjetprintheads are rotated to transfer ink to one or more printhead transfersurfaces. The gas bearing system and/or printhead transfer surface canbe positioned above, below, or above and below the substrate duringprinting. In some embodiments, the printing can comprise inkjet printingdirectly to a substrate. In such embodiments, the print module packagecan comprise an inkjet printhead. For example, the print module packagecan comprise a SAMBA printhead module (FUJIFILM Dimatix, Inc., SantaClara, Calif.). The gas bearing system and/or inkjet printhead can bepositioned above, below, or above and below the substrate duringprinting.

The positioning of the gas bearing system relative to the substrate cancomprise controlling the size of the print gap by controlling a flow offluid through at least one of the first and second manifolds. In someembodiments, the positioning can comprise maintaining a positive flow offluid from the first manifold and through the first plurality of fluidchannels and maintaining a negative flow of fluid into the secondplurality of fluid channels and through the second manifold. Thepositioning can comprise adjusting the flow of pressurized gas, vacuum,or both, to control the size of the print gap, gas bearing gap, or both.A control unit can be used to effect control of a pressurized gassource, a vacuum source, or both.

In some embodiments, the print gap can be defined as a distance of fromabout 5 μm to about 100 μm, for example, from about 20 μm to about 30μm, or about 25 μm. The method can maintain or provide a print gap by,for example, flowing an inert gas at a pressure of from about 10 psig toabout 200 psig, from about 30 psig to about 90 psig, from about 50 psigto about 70 psig, or about 60 psig, through the first plurality of fluidchannels. The positioning can further comprise pulling a vacuum throughthe second plurality of fluid channels at a negative pressure of fromabout −3.0 psig to about −13 psig, from about −5.0 psig to about −10psig, or about −7.5 psig. In some cases, the printing can compriseprinting onto a first surface of a substrate, wherein the substrate hasa second surface opposite the first surface, and the method furthercomprises positioning a second gas bearing system adjacent the secondsurface of the substrate and opposite the first gas bearing system. Thesecond gas bearing system can be configured to position the firstsurface of the substrate and to maintain a desired print gap. The secondgas bearing system can be used instead of, or in addition to, the firstgas bearing system.

Various embodiments of the present teachings relate to apparatuses andmethods for using air bearings for maintaining and controlling print gapand for controlling the environment surrounding the inkdeposition-printing process. For example, ink deposition can be carriedout in a non-oxidizing environment. In some embodiments, the printheadis mounted in a gas bearing housing so that the set gap is fixed at acertain distance, which can be as close to zero mm as practical. The setgap corresponds to the distance between the transfer surface of theprinthead and the end surface of the gas bearing housing. The gasbearing gap is the distance between the end surface and the substrate.Whether the substrate moves under the printhead and/or the printheadmoves over the substrate, either way, there is relative motion betweenthe printhead and the substrate. By pressurizing the fluid passagewaysof the gas bearing housing, gas flows out the openings in the housingand maintains the gas bearing gap between the gas bearing housing endsurface and the substrate. By this means, the print gap becomes the sumof the gas bearing gap and the set gas such that the print gap iscontrolled by these other two gaps. Fine changes, for example, on theorder of microns, can be made to the print gap by changing the gaspressure in the gas bearing housing. The flow of gas from the gasbearing housing to the exhaust creates an environment filled with thebearing gas. If the ink is sensitive to oxygen gas, a non-oxygen gasand/or inert gas such as nitrogen gas, for example, can be used toprovide a non-oxidizing environment. The process of evaporating liquidink within or on the printhead can cause solvent vapors to be produced.The exhaust opening allows both the removal of nitrogen gas injected bythe gas bearing system and the removal of the solvent vapors evolvedduring evaporation of liquid ink.

In some embodiments, pressure and vacuum sources are both employed indefining a desired print gap. In some embodiments, a vacuum source and anitrogen gas pressure source are provided. These sources are disposedfor fluid communication with respective channels in a gas bearinghousing, for example, disposed about a printhead, and thus a gas bearinggap can be established. The print gap can be variable relative to thebearing housing. The gas bearing housing and printhead can be disposedadjacent a substrate, for example, glass. The printhead can deposit filmmaterial, for example, an ink, comprising a film-forming materialdissolved or suspended in a carrier fluid, on the substrate. In someembodiments, the substrate is supported via a chuck with a gas lift orgas bearing system. In some embodiments, the substrate is supported viaa vacuum chuck in contact with the substrate.

As mentioned above, the gas bearing system of the present teachings canbe used alone or in combination with one or more additional gas bearingsystems. The additional gas bearing system can utilize any gas ormixture of gasses. The additional gas bearing system can use the same ordifferent gas or gaseous mixture as contained in a gas enclosure system,for example, a system that encloses a thermal printing operation. Insome embodiments, air bearings use an inert gas, for example, nitrogengas, one or more noble gasses, or a combination thereof. Gas bearingsystems, as well as related methods and systems, that can be usedinclude those available from New Way Machine Components, Inc. of Aston,Pa. They can be used alone, or in combination with, the gas bearingsystems described in the present teachings. Devices, systems, methods,and applications for use relating to gas bearing systems can be used inconnection with the present teachings, including, for example, thosedescribed in U.S. Pat. No. 7,908,885 B2, which is incorporated herein inits entirety by reference. Gas bearing systems, as well as relatedmethods and systems available from Coreflow Scientific Solutions LTD. ofYoqneam, Israel, can also be used, alone or in combination with the gasbearing systems described in the present teachings. Devices, systems,methods, and applications relating to gas bearing systems that can alsobe used in connection with the present teachings include, for example,those described in U.S. Pat. No. 7,857,121 B2, U.S. Pat. No. 7,604,439B2, U.S. Pat. No. 7,603,028 B2, and U.S. Pat. No. 7,530,778 B2, whichare incorporated herein in their entireties by reference.

Aspects of the present teachings can be practiced, for example, inconnection with the teachings of U.S. Patent Application PublicationNos. US 2008/0311307 A1, US 2008/0311289 A1, US 2006/0115585 A1,US2010/0188457 A1, US 2011/0008541 A1, US 2010/0171780 A1, and US2010/0201749 A1, and U.S. Patent Application No. 61/521,631 entitled“Face-Down Thermal-Jet Printing Apparatus and Methods,” which areincorporated herein in their entireties by reference.

FIG. 1 is a cross-sectional view of a gas bearing system 20 inaccordance with various embodiments of the present teachings. Gasbearing system 20 comprises a housing 22 that comprises a sidewall 24.Sidewall 24 comprises an exterior surface 26 and an interior surface 28.Interior surface 28 defines an interior cavity 30 that is configured toreceive a print module package 32. Interior surface 28 terminates at acavity opening 34 of interior cavity 30. An end surface 36 is disposedbetween interior surface 28 and exterior surface 26. Opposite endsurface 36 is an annular end portion 38 comprising a second cavityopening 40. Second cavity opening 40 can comprise a through hole 42. Afirst aperture 44 and a second aperture 46 can be located on end surface36. Extending from first aperture 44 can be a first fluid channel 48that extends into sidewall 24 of housing 22. A second fluid channel 50can extend from second aperture 46 into sidewall 24 of housing 22.

As seen in FIG. 1, print module package 32 can comprise a transfersurface 52 from which material can be transferred onto a substrate 56,and more specifically substrate surface 57, to form a deposited material54. A print gap 58 is defined as the distance between transfer surface52 and substrate surface 57. A gas bearing gap 60 is defined as thedistance between end surface 36 and substrate surface 57. A set gap 62is defined as the difference between the gas bearing system gap 60 andprint gap 58, which is the same as the distance between transfer surface52 and end surface 36.

FIG. 2 is a schematic, cross-sectional view of a gas bearing system 120in accordance with various embodiments of the present teachings. Gasbearing system 120 comprises a housing 122 that in turn comprises asidewall 124. Sidewall 124 comprises an exterior surface 126 and aninterior surface 128 defining an interior cavity 130. Interior cavity130 is configured to receive a print module package 132 through a cavityopening 134. Between exterior surface 126 and interior surface 128 is anend surface 136. A second cavity opening 138 can be located oppositecavity opening 134. End surface 136 can comprise a first aperture 140and a second aperture 142. A first fluid channel 144 can extend fromfirst aperture 140 into sidewall 124 of housing 122. A second fluidchannel 146 can extend from second aperture 142 into sidewall 124 ofhousing 122.

As seen in FIG. 2, first fluid channel 144 and second fluid channel 146can be in fluid communication with a first manifold 148. End surface 136can further comprise a third aperture 150, a fourth aperture 152, afifth aperture 154, and a sixth aperture 156. Third fluid channel 158,fourth fluid channel 160, fifth fluid channel 162, and sixth fluidchannel 164 can extend respectively from third aperture 150, fourthaperture 152, fifth aperture 154, and sixth aperture 156 into sidewall124 of housing 122. Third fluid channel 158, fourth fluid channel 160,fifth fluid channel 162, and sixth fluid channel 164 can be in fluidcommunication with a second manifold 166. In some embodiments, apressurized gas source 168 is in fluid communication with first manifold148. In some embodiments, a vacuum source 170 is in fluid communicationwith second manifold 166. A transfer surface 172 of print module package132 can be configured to deposit a material, for example, a film-formingmaterial, on a substrate. Deposited material 174 can be located onsubstrate 176 and more specifically on substrate surface 178. A printgap 180 can be defined as the distance between transfer surface 172 andsubstrate surface 178. A gas bearing system gap can be defined as thedistance between end surface 136 and substrate surface 178. A set gapcan be defined as the distance between end surface 136 and transfersurface 172. In some embodiments, a second gas bearing system 186 isprovided. Second gas bearing system 186 can comprise a plurality ofapertures 188 in fluid communication with a plurality of fluid channels(not shown). Apertures 188 can face a second substrate surface 190 ofsubstrate 176.

FIG. 3 is an exploded view of a gas bearing system 220 in accordancewith various embodiments of the present teachings. Gas bearing system220 can comprise a plurality of fasteners 222 to secure together a faceplate 224, a manifold assembly cover 226, a manifold assembly base 228,and a base plate 230. Fasteners 222 can comprise a first fastener 232, asecond fastener 234, a third fastener 236, and a fourth fastener 238.Face plate 224 can comprise an end surface 240. End surface 240 canreceive fasteners 222. Extending into face plate 224 from end surface240 can be provided a first fastener hole portion 242, a second fastenerhole portion 244, a third fastener hole portion 246, and a fourthfastener hole portion 248. Face plate 224 can comprise an exteriorsurface 250 and an interior surface 252. Interior surface 252 can definean interior cavity portion 254 as well as a first interior cavityopening 255. A plurality of fluid channel portions 256 can be disposedin face plate 224 between interior surface 252 and exterior surface 250.Each fluid channel portion 256 can terminate at a respective aperture onthe end surface of face plate 224 (not shown).

Manifold assembly cover 226 can comprise a first fastener hole portion258, a second fastener hole portion 260, a third fastener hole portion262, and a fourth fastener hole portion 264. The fastener hole portionscan be disposed between an exterior surface 266 and an interior surface268 of manifold assembly cover 226. Interior surface 268 can define aninterior cavity portion 270. A plurality of fluid channel portionsincluded within a complementary manifold portion 274 can be disposedbetween interior surface 268 and exterior surface 266.

Manifold assembly base 228 can comprise a first fastener hole portion276, a second fastener hole portion 278, a third fastener hole portion280, and a fourth fastener hole portion 282. Fastener hole portions ofmanifold assembly base 228 can be positioned between exterior surface284 and interior surface 286 of manifold assembly base 228. Interiorsurface 286 can define an interior cavity portion 288. Exterior surface284 and interior surface 286 can also define between them a plurality offluid channel portions within a complementary manifold portion 292. Aport receiving aperture 294 can extend from exterior surface 284.

Base plate 230 can comprise a first port 296, a second port 298, and athird port 300. A first fluid line 302 can be connected to first port296. A second fluid line 304 can be connected to second port 298. Athird fluid line 306 can be connected to third port 300. Face plate 230can comprise a main base plate portion 308. Main base plate portion 308can comprise an interior cavity portion 310 as well as a second interiorcavity opening 312. An interior base surface 314 can face manifoldassembly base 228. An exterior base surface 316 of base plate 230 canface outwardly in a manner similar but opposite to end surface 240 offace plate 224. A plurality of print module package adjustment screwreceiving holes can be disposed in exterior base surface 316. These caninclude first print module package adjustment screw receiving hole 318and a second print module package adjustment screw receiving hole 320.Other adjustment screw receiving holes can be provided, for example, onefor each adjustment screw on a print module package. Base plate 230 canfurther comprise a flange 326. Flange 326 can be configured forattachment, for example, to an actuator, a robotic arm, a rotatingactuator, a support piece, or the like. Flange 326 can comprise a firstflange fastener receiving hole 328, a second flange fastener receivinghole 330, a third flange fastener receiving hole 332, and a fourthflange fastener receiving hole 334.

FIG. 4 is a left, bottom perspective view of gas bearing system 220shown assembled and adjacent a print module package 336. First fastener232, second fastener 234, third fastener 236, and fourth fastener 238are shown disposed through end surface 240 and secure together faceplate 224, manifold assembly cover 226, manifold assembly base 228, andbase plate 230. Print module package 336 comprises a printhead 338 asits apex. Printhead 338 can comprise one or more transfer surfaces 340.Print module package 336 can comprise one or more print module packageadjustment devices such as linear adjustment screws. FIG. 4 shows afirst print module package adjustment screw 342, a second print modulepackage adjustment screw 344, and a third print module packageadjustment screw 346. Any number of adjustment screws can be used, forexample, three or four. Linear adjustment screws can be used to alignthe theta x and y rotation of printhead 338 and/or to make transfersurface 340 of printhead 338 flush, recessed, parallel to, and/orslightly extended from end surface 240 of gas bearing system 220. Firstprint module package adjustment screw 342 and second print modulepackage adjustment screw 344 can be secured to, mounted in, and/oradjustably disposed in first print module package base flange 350. Thirdprint module package adjustment screw 346 and one or more other printmodule package adjustment screws can be secured to, mounted in, and/oradjustably disposed in second print module base flange 352.

Print module package 336 can be fastened to gas bearing system 220 usingany of a variety of fasteners. In FIG. 3, two magnets 322 and 324 areshown mounted in the underside of base plate 230. Magnets 322 and 324can be aligned with corresponding magnets (not shown) on print modulepackage 336 or aligned with a magnetically susceptible metal materialthat is a part of print module package 336, for example, base flanges350 and 352 shown in FIG. 4. Any number of magnets can be used.

Interior cavity 354 can result from the assembly of gas bearing system220 including interior cavity portion 254, interior cavity opening 255,interior cavity portion 288 (FIG. 3), and interior cavity portion 310(FIG. 3). A plurality of apertures 360 are shown disposed on end surface240 between exterior surface 250 and interior surface 252. A pluralityof manifolds 362 are contained within manifold assembly cover 226 andmanifold assembly base 228.

FIG. 5 is a perspective view of gas bearing system 220 upside down, andassembled with a print module package 336. Print module package 336 hasbeen placed into interior cavity 354 and first print module packageadjustment screw 342, second print module package adjustment screw 344,and third print module package adjustment screw 346 are utilized toadjust the relative positioning between print module package 336 and gasbearing system 220. This configuration presses first print modulepackage base flange 350 and second print module package base flange 352against exterior base surface 316 of base plate 230.

FIG. 6 is a right, bottom perspective view of gas bearing system 220 andprint module package 336 in an assembled configuration. Printhead 338and transfer surface 340 are visible through first interior cavityopening 255 and are surrounded by the plurality of apertures 360disposed on end surface 240.

FIG. 7 is a perspective view of gas bearing system 220, connected to anactuator 364 through flange 326. Actuator 364 can comprise an actuatormotor 366 and a rotatable actuator faceplate 368. Flange 326 can besecured to actuator face plate 368.

Load-lock features and methods of using them, that can be utilized inaccordance with various embodiments of the present teachings, includethose described, for example, in U.S. Patent Application Publication No.US 2010/0201749 A1, which is incorporated herein in its entirety byreference.

All publications, patents, and patent applications mentioned in thisspecification are herein incorporated by reference to the same extent asif each individual publication, patent, or patent application wasspecifically and individually indicated to be incorporated by reference.

While embodiments of the present disclosure have been shown anddescribed herein, it will be obvious to those skilled in the art thatsuch embodiments are provided by way of example only. Numerousvariations, changes, and substitutions will now occur to those skilledin the art without departing from the disclosure. It should beunderstood that various alternatives to the embodiments of thedisclosure described herein may be employed in practicing thedisclosure. It is intended that the following claims define the scope ofthe disclosure and that methods and structures within the scope of theseclaims and their equivalents be covered thereby.

What is claimed is:
 1. A printing system comprising: a gas enclosuredefining an interior; a printing apparatus housed in the interior of thegas enclosure and configured for printing a substrate, the printingapparatus comprising: a printhead module configured with at least oneprinthead for deposition of a film-forming material on a first surfaceof a substrate; said substrate having a second surface opposite thefirst surface; a gas bearing system configured to support the substrateon the second surface with a bearing gas, wherein the gas bearing is influid communication with an environment surrounding an inkdeposition-printing process; and a control unit for controlling the gasbearing.
 2. The printing system of claim 1, further comprising anexhaust system to remove solvent vapors produced from the deposition ofthe film-forming material on the first surface of the substrate.
 3. Theprinting system of claim 2, the gas bearing comprises a plurality ofpressurized gas channels.
 4. The printing system of claim 3, wherein thecontrol unit can be used to effect control of a gas source in flowcommunication with the pressurized gas channels.
 5. The printing systemof claim 2, the gas bearing comprises a plurality of pressurized gaschannels and a plurality of vacuum channels.
 6. The printing system ofclaim 5, wherein the control unit can be used to effect control of a gassource in flow communication with the pressurized gas channels, controlof a vacuum source in flow communication with the vacuum channels, orboth.
 7. The printing system of claim 1, wherein the environmentsurrounding an ink deposition-printing process is a controlled gasenvironment.
 8. The printing system of claim 7, wherein the controlledgas environment is a non-oxidizing environment.
 9. The printing systemof claim 8, wherein the non-oxidizing environment is provided by anon-oxygen gas.
 10. The printing system of claim 7 wherein thecontrolled gas environment is an inert gas environment.
 11. The printingsystem of claim 10, wherein the inert gas environment is provided bynitrogen.
 12. The printing system of claim 10, wherein the inert gasenvironment is provided by nitrogen in combination with at least onenoble gas.
 13. The printing system of claim 1, wherein the at least oneprinthead is an inkjet printhead.
 14. The printing system of claim 1,wherein the substrate is a glass substrate.
 15. The printing system ofclaim 1, wherein the gas bearing is configured with heating channels andcooling channels for regulating the temperature of the bearing gas.